Method of making fabricated articles



June 14, 1949. v J. GREGG METHOD OF MAKING FABRICATED'ARTICLES 2 Sheets-Sheet 1 Filed Sept. 29, 1944 W inimumW" INVENTOR. J O N 6 RE 6 6 AT ToQA/EY June 14, 1949. J, GREGG METHOD OF MAKING FABRICATED ARTICLES 2 Sheets-Sheet 2 Filed Sept. 29, 1944 INVENTOR. JON GREGG rroplvgy Patented June 14, 1949 METHOD OF MAKING FABRICATED ARTICLES Jon Gregg, New Hope, Pa.

Application September 29, 1944, Serial No. 556,399

3 Claims. 1 This invention relates to fabricated articles and methods of making the same. It is particularly directed to an improved process for making outsoles for footwear, rugs and the like articles.

An object of this invention is to improve the method described in my co-pending application.

Serial No. 401,179, filed July 5, 1941, issued as Patent No. 2,361,938 on November 7, 1944.

Another object of this invention is to' provide a process of the character described comprising winding a flexible strip with moldable, vulcanizable, thermosetting or thermoplastic material covering substantially an entire side, and then causing the material to soften, flow and unite the windings of the strip without any substantial overflow at the top and bottom surfaces of the wound strip.

Another object of this invention is to provide an economic process of the character described which will result in a strong, durable and comfortable outsole.

Other objects of this invention will in part be obvious and in part hereinafter pointed out.

The invention acccordingly consists in the combination of steps, features of construction, combinations of elements, and arrangement of parts which will be exemplified in the method and construction hereinafter described, and of which the scope of application will be indicated in the following claims.

In the accompanying drawing, in which is shown one of the various possible illustrative embodiments of this invention, a

Fig. 1 is a side elevational view of apparatus for carrying out the invention;

Fig. 2 is a top plan view of the winding table used in carrying out the invention;

Fig. 3 is a partial, side elevational view of the sole as it comes off the winding table, with parts broken away;

Fig. 4 is a cross-sectional view taken on line 4-4 of Fig. 3; I

Fig. 5 is a top plan view of a sole made in accordance with the process embodying the invention;

Fig. 6 is a cross-sectional view taken on line 66 of Fig. 5;

Fig. 7 is a top plan view of a temporary mold used to carry out the inventiveprocess;

Fig. 8 is a cross-sectional view taken on line 8-8 of Fig. 7;

Fig. 9 is a top plan view of the mold used for pressing the outsoles under heat and pressure;

to totally cure or vulcanize the rubber.

, Fig. 10 is a view similar to Fig. 4 and illustrating a modification of the invention;

Fig. 11 is a view similar to Fig. 10 and illustrating another modification of the invention;

Fig. 12 is a view similar to Fig. 11, but showing the sole after molding under heat and pressure; and

Fig. 13 is a transverse, cross-sectional view illustrating a modification of the inventive process.

In my co-pending application Serial No. 401,179, issued as Patent No. 2,361,938 on-Novemher 7, 1944, there is described a method of making an outsole comprising the application of a strip of uncured rubber or synthetic moldable material in tacky condition to a side of a braided strip, then winding the stuck-together strips into the general form of an outsole, and pressing the same in a mold under heat and pressure to produce the outsole. In said co-pending application the strip of uncured rubber or other moldable material is defined as being of less width than the braided strip, and the edges of the moldable strip aredefined as being disposed inwardly of the edges of the braided strip. The reason for spacing the edges of the strip of moldable material from the braided stripis so that during the molding process the rubber will not flow over the top and bottom of the braided strip and gum up the surfaces of the sole. After the molding operation, the thermoplastic or moldable material flows substantially to the upper edges of the braid. Thus in curing the sole, the-pressure of the mold and the heat of the vulcanization cause the rubber to flow, and in the finished sole the rubber is actually as wide as the braid.

In the present invention the strip of moldable material is substantially as wide as the braided strip but does not fiow over the top and bottom surfaces of the sole during the vulcanizing or molding process, or while the sole is subjected to heat and pressure.

' The prevention of overflow or gumming up of the tread surface can be accomplished in several ways. The first is by the use of semi-cured rubber, that is the rubber compound is subjected to a period of vulcanization or curing insufiicient Another way of accomplishing the desired result is to use flow resisting rubber. The achievement of such a product is entirely dependent on the amount of sulfur and the type and amount of accelerator used so that the rubber will begin curing prior to too great a pressure being applied in the mold. If a certain non-cured rubber mix or compound requires a certain time, a certain temperature and pressure, to wholly cure it, then additional accelerator is added so that the compound will cure faster at the temperature and pressure used, that is it will cure before it has a chance to flow over. If a Captax-Altax-Methyl Tuads acceleration with Kalite No. 1 filler is used, it will probably give a better rubber compound which is flow resistant. It may be neces sary to add litharge to the compound to get a fast enough cure.

Another way of accomplishing the desired result is to use a thermosetting resin which is dipped or sprayed on all sides with a thermoplastic resin. This could be accomplished by extruding the thermosetting resin andth'e'n passing it through rollers whieh woma coatit with a thermoplastic resin. The thermosetting resin should cure at about 50 below the curing temperature, and the thermoplastic resin should cure around "before the curing temperature. Thus the thermos'ettiiig resin 'will cure before the thermoplastieresin. The accelerated curing will retard the fiOW. ihe-thermos'etting resin might also be cured outsidedf the pres's and the thermoplastic resincure'd inthepr ess.

In Fig. 1 of the drawing, there is shown apparatus lfl to'c'arry' outgpa'r t of the inventive process. The apparatus lllcomprises an extruder I l for extruding a strip 2 of moldable the'rmoplastic, thermosettin'g, or vuloanizable material. The strip 1 2 pass'es between i OlIe'is 14 -for applying a tackifierto-the strip i; it is'not-sufficiently tacky in itself. The lower rol lermay run in a trough I5 and a solvent for the moldable material may be applied to the' -upp'enrolle'r 'by means of adrip tank I l t. The strip l'2 is united with ia iflexible fibrous strip su'ch as a braided strip I'L by pressing between rollers I 8. *The strip H may comprise braided fibrous yar-n such as cotton, wool, jute, *hem'p or the -like fibers, or may "be of any suitable strip of -flexible -materia1 preferably fibrous-porous or absorbent material so'that the moldable"material may: penetrate the same during-the molding prdeessas will appear hereinafter. Instead-Of a isolvent, a-plasticizer or an adhesive may be' applied to strip L2; or heat may be applied (as by heated rollers) to cause ittobecome tacky. If desired-the material maybe extruded i'n-taekycondition. =Also if-"desired, an

adhesivemay be applied to the strip 1 I l to cause strip [2 tobeunitedtherewith.

The pressed-togetherstrips mayipass' through a guide -"--a nd "be wound on the usual Winding table 2 l. -As:shown -in Fig.-4 of the drawing, the strip i2 is substantially as wide as the braided strips-l7. '1he=strip l2 may, as stated above, be semi-cured. rubber compoun'cL- that :is, it is a rubbercompound -which,-after=ai period of vulcanization or self curing shows .chemical and physical properties such astensile; swell in gasolene, hardness, elongation, shape, etc., which are-substantially different than those-obtained by a further period of vulcanization or-self-curing.

The-solvent for-semi-cured rubber to render it tacky may be: in the form-of low grade gasolene,

aromatic hydrocarbons such as -benzene,-- or rubbercement can beusedwhichcould be spread on the semi-cured rubber. The strip l2 may also be in the'form of a flowresisting -rubber compound provided with-excess amount oraccelerator than -isusual for curing atthe temperature, pressure im: required for a normal amount of accelerator. The strip I'Z -may also be made of -a plastic which will. cureat'lowtemperature prior 4 to application of pressure. A thermoplastic resin could be used.

After the strip is wound on table 2|, it may be remolded or compressed in the temporary mold or premolder shown in Figs. '7 and 8. The moid 3!] comprises a pair of complementary mold members 31 and 32 having cutouts to receive the sole. Mold member 32 is slidable in mold member "'31 and maybe closedlby means of clamped levers 3'3. Hand'pressure'is applied to cause the windings of the outsole to stick together sufiiciently so that the outsole can be handled, stored *andtranspofted'to the permanent molds. A top plate 35 may be used to press the sole into the mold. The moldable material must be sufiicientl'y tacky or adhesive to permit the turns to :stick together zsufiiciently to permit handling of thesole. Thereafter the sole is placed in a permanent mold 40 shown in Fig. 9, and the moldable material is cured under heat and pressure.

Th-e m'old lt likewise comprises complementary 'm old members J62 and 43 having :complementary cutouts 4 2a and 'xllsa toreceive the sole. A top plate "45 may 1be employed ito press the sole into the mold. A plunger which fits into theimold may be usediinsteadlof :aztopplate.

In Fig. 5 there:is-"showmaisolers: in'accordance with the present invention. During the curing, the semicured ior flow-resisting rubber fiows an'd penetrates into'the intersticesofithe'braidtonnite the windings. With therprocessadescribed herein 'there will be substantially 'no fiow :over tthe top and bottomfofithesole.

In Fig. 10" there iswshown-ia -woundi'sole-priorzto molding under pressure and'heat. Insaid figure ithere .s-howna strip 1211 which replaces the istr-ip12. Strip 12a :comprisesea core 'fifl .of'thermosetting material coated by a eoating'fil -.of thermoplastic material :asi'clescribed. above. The thermos'etting material curesfaster than the curing temperature :ior "the thermoplastic .material and since it cures faster, it does not haveaa chance to flOWn'OVBI the .top and: bottom of' the sole.

In --Fig. '11 there'is. shown a wound :sole prior to molding. =In makingisa-id sole thereisemployed 1a moldable strip 121) *whichds thicker in the middle than the'ends. The strip IN; is alsosubstantially'aswide asithe brai'dedtstrip I1. During the molding process \there will abe rsubstantially no overflow because-there. islessimoldable material at that-edges of-ltheistrip thaniatrthe middle.

In Fig. 13 there .issi'llustrated another modifia strip 20 of moldable.or thermoplastic material, either-synthetic material or-rcrude rubber. The upper and lower. edges. of -th ...strip I20. may be semi-cured b passing the strip lbetween a;pair of heated blocksw. Tfllmstripflcv may also-.be thicker atthe middle'than at theedgeslifdesired. When the strip is combined with 'the braidedstrip' and placed inthe'mold, the. middle part of the strip will flow more than the "edges, and therebypVer'fiowbf themolda'ble material will be "prevented. During the molding process it has been found that the rubber flows more'at the topand bottom edges than'at the middle because the upper and lower edges of the strip are oloser -toi-the heated parts of the moId. -By first semi-outing the edgesx-a retarding 0f flow iatthe edges will:'result during the final curing operation.

Plastic 'stripszcould;be'adhereduto. the braid by theauseaof watereandaalcoholtsolutions: for eexample, Durez resin, certain amberlite resins of Rohm and Haas, and certain Bakelite resins are water soluble. Eastman Tenite and Vinylite are soluble in esters and ketones such as acetone, methyl-ethyl katone, ethyl acetate. The polystyrene plastics are also soluble in ketones and esters. The plastic strip can be passed through a roll coated with one of the suitable solvents, so that it will soften. It is possible to cure rubber and plastics without heat and pressure or only by the application of pressure and without heat. There are rubber accelerators and plastic catalysts to do this self-curing It is also possible to apply a solvent to the plastic and then by pressure alone to cause the plastic to flow into the braid. When using rubber or resin strip binders, the same may be given tackiness by spraying with adhesive. Rubber may be sprayed with rubber cement. A tacky resin may be added to the base resin to make the strip tacky. Rosin, pine tar or parafiux are good tackifiers for rubber and would Work with plastics.

A solution of rubber or a resin could be sprayed on the braid, allowed to dry and then brought back to a tacky condition by application of a solvent to the rubber or resin. Furthermore, such resin or rubber may be rendered adhesive by application of heat prior to winding so that the turns will stick together to permit handling.

Another method of carrying out the invention is to coat both sides of a plastic strip with a tackifier or with an adhesive or applying a solvent to opposite sides of the plastic strip and then pressing the plastic strip to one side of a flexible fibrous strip, such as braided cotton, jute, manila, or the like material, then Winding the braided strips together into the general form of an outsole, then pressing the outsole in a. temporary mold 311, and then molding in a mold 413 under heat and pressure. The fact that the plastic or rubber strip is tacky on opposite sides, permits one side to be applied to the braided strip and also permits the windings of the strip to stick together particularly when pressed in the temporary mold 30 to permit handling as it is transported to the mold 40 for the final curing and molding operation.

Although there has been above described a process of making an outsole, it will be understood that other articles may be made in accordance with the process described above. Thus rugs can be made by Winding the fibrous flexible strip spirally together with the thermosetting, thermoplastic or other moldable material or uncured rubber. Furthermore, instead of winding the strip it may be arranged in parallel layers. After the molding process, various articles may be died out. Thus, for example, a sole may be died out of a layered article made in the manner above described.

Furthermore, although the drawing describes the fibrous strip l2 as being a braided strip, it will be understood that any suitable strip may be substituted such as a woven or knitted strip, or a rope.

It will thus be seen that there is provided a device and method in which the several objects of this invention are achieved, and which is well adapted to meet the conditions of practical use.

As various possible embodiments might be made of the above invention, and as various changes might be made in the embodiment above set forth, it is to be understood that all matter herein set forth or shown in the accompanying drawing is to be interpreted as illustrative and not in a limiting sense.

Having thus described my invention, I claim as new and desire to secure by Letters Patent:

1. A process of making a layered article, comprising arranging strip portions of semicured rubber between strip portions of flexible fibrous material of the same Width so that the semicured material is disposed between the strip portions of the flexible fibrous material, and then subjecting the article to heat and pressure in a mold for curing the semicured rubber to unite the flexible strip portions.

2. A process of making a layered article of a thickness equivalent to the width of strips of flexible fibrous material, comprising arranging strip portions of said fibrous material in layers with intervening strips of moldabl material which are thicker at their midportions than at the edge thereof, pressing said strip portions together and subjecting the article to heat and pressure in a mold for causing the moldable material to soften and unite adjacent flexible strip portions.

3. A process of the character described, comprising semi-curing the edge portions of a strip of vulcanizable material, then applying the strip to one side of an elongated flexible strip of fibrous material, winding the strips together in the form of an outsole and vulcanizing in a mold under heat and pressure.

JON GREGG.

REFERENCES CITED The following referenlces are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,205,345 Hatfield Nov. 21, 1916 2,307,401 Gregg Jan. 5, 1943 2,361,936 Gregg Nov. '7, 1944. 

